MIL-STD-1530C(USAF)
5.3.4.3 Inspection program.
An inspection program shall be conducted as an integral part of the full-scale aircraft structure durability test. The inspection program shall be approved by the USAF. The objectives of the inspection program shall be to detect damage as early as possible, to provide crack growth data, and to minimize the risk of a catastrophic failure during testing.
5.3.4.4 Teardown inspection and evaluation.
At the end of the full-scale durability test, including any scheduled damage tolerance tests, a destructive teardown inspection program shall be conducted. This inspection shall include disassembly and
laboratory-type inspection of those critical areas identified in design as well as additional critical structure identified during testing and during close visual examination while disassembly is performed. Fractographic examinations shall be conducted to obtain crack growth data and to assist in the assessment of the initial quality of the aircraft structure. The EIFS distribution shall be derived from the damage discovered during testing and the teardown inspection. The methods, procedures, and data used to determine the EIFS shall be documented and delivered to the USAF as part of the acquisition contract to serve as a basis to validate any future changes in analytical methods. Prior to teardown, consideration should be given to evaluation of the effectiveness of the anticipated NDI methods that may be applied to fielded aircraft.
5.3.5 Damage tolerance tests.
A damage tolerance test program shall be conducted using the repeated application of the flight-by-flight design service loads/environment spectrum. Thermal environment effects shall be simulated, along with the load application on aircraft structures where operational environments impose significant thermal effects. The intent shall be to conduct damage tolerance tests on existing test hardware. This may include use of components and assemblies of the design development tests as well as the full-scale static and durability test articles. When necessary, additional structural components and assemblies shall be selected, fabricated, and tested.
5.3.6 Climatic tests.
Full-scale system-level climatic testing shall be conducted to identify potential corrosion problems in the field. Identification of fluid sources, trapped fluid locations, and improper drain paths shall be performed to the maximum extent possible. The results of this testing shall provide initial input for corrosion-related tasks in the Force Structural Maintenance Plan described in 5.4.3.
5.3.7 Interpretation and evaluation of test results.
Each structural problem that occurs during the tests described by this standard shall be analyzed to determine the root cause, corrective actions, force implications, and estimated costs. Examples of structural problems include but are not limited to: analytical shortfalls (measured loads, stresses, vibrations, etc., that differ from predictions), failures, cracking, yielding, corrosion, etc. The scope of and interrelation between the various ASIP tasks within the interpretation and evaluation effort are illustrated on figure 2 and figure 3. The results of these evaluations shall define corrective actions required to demonstrate that the strength, rigidity, damage tolerance, and durability design requirements are met and the associated risk reduction is achieved. The cost, schedule, and other impacts which result from correction of structural problems shall be used to make major program decisions such as major redesign, program cancellation, awards or penalties, and production aircraft buys. Structural modifications or changes derived from the results of the full-scale tests to meet the specified strength, rigidity, damage tolerance, and durability design requirements shall be substantiated by subsequent tests of components, assemblies, or full-scale article, as appropriate (see figure 3).
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